Staffan Zetterström and Fabian Niklas break down why the future of the foundry industry cannot rely on automotive alone and why non-automotive business is rapidly becoming the most strategic and profitable path forward.

With automotive volumes flattening, EV architectures reducing part count, and new competitors squeezing margins, the classic “wait for the rebound” mindset is no longer viable. This episode explains what is changing, which industries offer real opportunities, and what foundries must rethink to reach customers who don’t traditionally work with castings.

Whether you’re a foundry owner, commercial leader, or technical manager, this discussion provides a practical roadmap for expanding into new markets, building resilience, and taking control of your long-term business development.

Key Insights

* New industries are opening up, if you know where to look

Some sectors outside the automotive industry are quietly becoming gold mines for foundries. The opportunities are bigger than most expect.

* These customers don’t think like automotive, and that’s the advantage

When the purchasing logic changes, so does the way you win business. The rules are different and far more favorable for those who adapt.

* Speed matters more than you think!

In specific industries, your response time can outweigh your price. A simple shift in pace can unlock doors that were previously closed.

* The casting is only the beginning

In many applications, the casting itself is a small part of the total value. Knowing how the rest of the product comes together makes all the difference.

* Marketing becomes your new inbound engine

To get in front of industries that don’t know you, and don’t know they need you, communication becomes a strategic capability, not a nice-to-have.

* Visibility beats perfection

You don’t need millions of views. You need the right 10–14 people to see you, recognize you, and start a conversation. Being present in the right channels makes that happen.

“You’re not selling a 1,99€ lipstick; you’re selling trust!”

This episode highlights why diversifying beyond automotive isn’t optional anymore. It’s a strategic move that can unlock long-lived programs, higher margins, closer customer relationships, and a more stable future, but only if foundries build the commercial muscles needed to reach industries that operate very differently from the automotive industry.

Rather than waiting for the market to recover, this Gold Nugget outlines how to create your own demand, position your expertise, and win business in sectors that value engineering service, reliability, and sustainability.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes.

Until next time, keep casting strong!

Fabian and Staffan

Staffan Zetterström and Fabian Niklas take a closer look at the Rheocasting Masterclass by Casting-Campus GmbH. A practical, business-focused online learning format designed to help the foundry industry unlock new applications and profits with Rheocasting.

Whether you’re an engineer evaluating new processes, a commercial leader searching for fresh revenue streams, or a supplier who wants to understand where the industry is heading, this podcast provides a clear view of why Rheocasting is gaining traction now and how the proper knowledge can unlock an unfair advantage for anyone ready to move first.

Key Insights

* What the Masterclass covers: From solidification and rheological behavior to business development, application design, and market positioning.

* Lower alloy silicon ≠ lower opportunity: How Rheocasting compensates for castability challenges in giga- and megacastings, while improving tool life and performance.

* New applications advantage: Conductivity jumps from ~140 W/mK to nearly 200 W/mK with low-Si alloys, enabling new electronics and cooling concepts.

* Who’s joining?: Strong participation from Italy, the U.S., and India, with foundries, suppliers, and OEMs unified in the need to understand Rheocasting.

* Flexible global access: Six webinars, multiple meetings for different time zones, and a format that works for operators, engineers, sales teams, and management alike.

* Business first: Rheocasting success requires marketing, design collaboration, and early customer involvement; not just buying new equipment.

“Buying the machine is the easy part, the value is created when you build new business with it.”

This episode highlights how rising demand for high-performance components, shrinking automotive volumes, and the push for differentiation make Rheocasting a timely strategic move for foundries. With a format that is affordable, accessible, and designed for real-world implementation, the Masterclass aims to close the gap between technical capability and profitable business execution. It empowers foundries not just to make better parts, but to win new applications, build stronger customer relationships, and take control of their future in a rapidly changing market.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes.

Until next time, keep casting strong!

Fabian and Staffan

In this episode, Staffan Zetterström and Fabian Niklas travel to India, one of the world's most dynamic and rapidly growing die casting markets. Our guest, Tej Bambra, brings nearly four decades of industry experience and a lifetime of insight into how the Indian die casting landscape has evolved from manual casting in the 1970s to today’s robotics and closed-loop systems.

Key Insights

* India vs. China — how scale, demand, and government incentives shape both markets.

* Technology adoption — why most Indian die casters still rely on imported European and Chinese machinery, and how this affects cost competitiveness.

* Materials and innovation — the early steps in magnesium die casting and the maturity of aluminium smelting in India.

* Automotive outlook — from 4.9 million four-wheelers and 21 million two-wheelers today to a projected 10 million cars by 2030.

* EV growth and the two-wheeler backbone — how electrification could reshape India’s mobility sector.

* Global positioning — what it will take for India to narrow the gap to China and become a true manufacturing counterweight.

“The Future is bright, but we have to bridge the Gap in Technology and Scale”

Tej also reflects on the cultural and economic contrasts between Europe and India: while the West may be moving away from car ownership, in India, a car remains a symbol of status and freedom, and that demand is driving industrial growth.

This episode offers a grounded look at where Indian die casting stands today and how it’s preparing for the next decade of transformation.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes.

Until next time, keep casting strong!

Fabian and Staffan

This week, Staffan Zetterström sits down with Fabian Niklas, this time in a different role. Fabian is the driving force behind the new Marketing Accelerator for the high-pressure die casting industry.

If you’ve ever struggled to make your company visible beyond job ads and trade fairs, this episode is for you. Fabian explains why our industry has world-class technology but often hides it “in the drawer”, how to finally communicate benefits (not just features), and why consistent, smart content will attract the right customers and even AI search engines to your doorstep.

Key Insights

* Why great die casting innovations often remain invisible, and how to change that.

* How the Marketing Accelerator works: bi-weekly online meetups, peer feedback, and content accountability.

* Turning content into real leads and why mass press releases don’t work on Social Media.

* How AI search is changing how buyers find foundries and how to be discoverable.

* The power of consistency and uniqueness in technical B2B marketing.

* Building a personal brand that moves with you throughout your career.

Either you die a little bit every day, or you develop a little bit every day

Whether you’re responsible for business development, employer branding, or just curious about building your personal brand in die casting, the Marketing Accelerator is a free, community-driven workshop to learn, share, and grow. Invest a few hours, try the Marketing Accelerator, and see where it takes you.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes.

Until next time, keep casting strong!

Fabian and Staffan

Too much idle capacity, not enough profitable work? This episode is your field guide. Staffan Zetterström and Fabian Niklas welcome Dr. Per Jansson of Comptech (one of our sponsors) to map the fastest paths from Rheocasting theory to booked orders, as well as the small process tweaks that make buyers say “yes” to trials.

Key Insights

* From buzzword to backlog: How a few smart Rheocasting moves can turn idle capacity into booked work.

* Easy entry points: Where you can start with existing parts and alloys yet unlock fewer leaks, less porosity, and longer tool lifetimes.

* Heat Management is the new volume: Why thermal management parts are an overlooked market and what Rheocasting changes about fin height and thickness.

* Gigacasting productivity mindset: Where big structural ambitions meet gentler fill and why that combo matters for ductility and joining technologies.

* Winning the RFQ before it’s an RFQ: The positioning and proof steps that get buyers to say “yes” to a trial and come back for a program.

* Outlook by region: Who’s moving first and why; a quick tour across Japan & Korea, China, India, North America, and Europe.

Foundries need a new Playbook now!

If you’re staring at idle capacity, leaky problem parts, or RFQs that only talk price, this episode is your nudge to try something different. Start small, prove fast, and turn one stubborn part into the pilot that changes your pipeline.

Listen in for the “start on Monday” version of Rheocasting: where to begin without redraws, how to frame a low-risk trial, and which markets are buying right now.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes.

Until next time, keep casting strong!

Fabian and Staffan

This episode takes you far east into China. Staffan Zetterström and Fabian Niklas sit down with Tracy Feng, a long-time insider of the Chinese die-casting industry. From Shanghai, she brings a unique perspective on how the world’s largest automotive and die-casting market is evolving and what makes it so different from Europe.

Key Insights

* Gigacasting in China: while Europe still debates, Chinese OEMs are already in mass production and moving to the next challenge.

* The rise of magnesium & thixomolding: why these technologies are gaining momentum and what makes China a hotspot for innovation.

* Collaboration culture: how automakers, suppliers, universities, and machine builders work together and why that accelerates change.

* China’s speed advantage: what drives the rapid adoption of new technologies and the sheer pace of industrial transformation.

* Global ambitions: why Chinese die casters and automakers are looking beyond their home market, and what that could mean for Europe.

* Beyond automotive: how applications in robotics, drones, 6G, and new mobility forms are reshaping the die-casting landscape.

Learn about the Next Wave in China

Tracy’s insider view reveals not just where China is today, but where it’s heading, and why it matters for anyone in the global die-casting and foundry industry. Don’t miss this unique glimpse behind the curtain of the Chinese market, full of lessons, surprises, and signals for the future.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes.

Until next time, keep casting strong!

Fabian and Staffan

We all heard the news about the current situation of the European automotive market. Staffan Zetterström and Fabian Niklas unpack the latest data and trends shaping the European automotive landscape based on the published quarterly reports of the OEMs. With sales results in, shifting consumer behaviour, and new players rising, the picture is far from simple.

Key Takeaways:

* Sales Numbers under the Microscope:

What do the most recent OEM results tell us? Revenues, profits, and volumes all point in different directions, and the implications run deep.

* The Distribution Story:

From small cars to premium EVs and SUVs, the mix of what people are buying in Europe is changing. But are we moving as fast as we think?

* The Chinese Acceleration:

Chinese carmakers are gaining ground at record speed. How significant is their presence in Europe today, and how disruptive could it become tomorrow?

* The Foundry Industry Impact:

Automotive shifts ripple straight into the foundry world. Which trends will squeeze suppliers hardest, and which could open unexpected doors?

* The Way Forward:

With pressure on all sides, what strategies are left for foundries and suppliers to not only survive, but thrive?

Listen closely and get a head start!

The European automotive industry is in a state of flux, and that matters because automotive is still the foundry industry’s single biggest customer. If your business depends on supplying the automotive sector, these insights aren’t optional; they’re survival material. Listen to Gold Nugget 52 and start the implementation process.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes. Until next time, keep casting strong!

Fabian and Staffan

In this nearly detective-style episode, Fabian Niklas and Staffan Zetterström break from opinion and prediction to bring you something else entirely:data. Open source, fact-based insights that paint a sobering picture of where the die-casting market is headed and what every foundry leader needs to understand.

Key Takeaways:

* The Global Car Market Is ShiftingFrom 2014 to today, the production landscape has changed dramatically. Europe is no longer holding its ground, while China continues to accelerate. Despite some forecasts predicting smooth growth, a closer look reveals regional divergence that shouldn't be ignored.

* The EV EffectThe industry’s dependence on combustion engines is rapidly becoming a liability. EVs require fewer cast components, fewer shots, and radically different platforms. In the space of just five years, the average number of casting shots per car is expected to drop dramatically, even as total vehicle output grows.

* Why This MattersIt’s not just about fewer castings. It’s about platform shifts, software priorities, changing consumer preferences, and new forms of transportation entirely. From software-defined vehicles to new ownership models, foundries must adapt to an industry where value creation has moved elsewhere.

* A Calculated Wake-Up CallWe’ve combined four critical data points to arrive at a clear message: the future volume of casting shots is under direct threat. Even in optimistic scenarios, the number of available projects is falling, and with it, the economic foundation of many foundries.

Your Input is Welcome!

This report isn’t the final word – it’s the beginning of a conversation. We invite you to challenge the assumptions, question the calculations, and contribute your insights. Regional deep-dives are already in the works, beginning with Europe.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes. Until next time, keep casting strong!

Fabian and Staffan

In this milestone 50th episode of Goldcasting, your hosts, Staffan Zetterström and Fabian Niklas, welcome Andreas Würzer from Handtmann, one of the few companies in Europe pushing megacasting forward with full force. While the rest of the world watches China sprint through the gigacasting evolution, Handtmann has already hit the ground running, without even waiting for a customer nomination.

Key Takeaways:

* A Strategic Gamble with Gigacasting in GermanyHandtmann invested in gigacasting before landing a contract. Why? Strategic foresight, market studies, and a commitment to pushing development, not waiting for it.

* Chinese Speed vs. German LegacyEurope’s brownfield limitations contrast with China’s greenfield advantage. Andreas Würzer explains why this slows down OEMs in Germany and what needs to change.

* Engineering as a DifferentiatorHandtmann hasn’t just bought a machine; they’re building capabilities. Simulation, topology optimisation, validation, and even additive manufacturing are baked into their development DNA.

* From Brochure to Business CaseAndreas Würzer shares what it really takes to convince OEMs. It is not PowerPoint presentations, but functional prototypes, real-world testing, and co-developed design spaces.

* Material MattersHandtmann is advancing the use of secondary alloys, even in structural parts, and views semi-solid casting as a productivity booster, particularly at lower temperatures, with improved flow and reduced wear.

* The Long ViewThis isn’t a one-shot bet. Andreas Würzer sees megacasting as entering its first evolutionary step in Europe. The real transformation is yet to come with better alloys, lighter walls, and smarter integration.

If you're waiting for the OEM, you're too late!

If you're serious about the future of casting, this episode is a blueprint for how to lead and take responsibility in a fast-changing industry. Tune in now. Learn from those who don’t wait for an OEM to make a decision, but instead take the initiative and do the groundwork themselves.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes. Until next time, keep casting strong!

Fabian and Staffan

In Gold Nugget 49, Staffan Zetterström and Fabian Niklas take a hard look at the economic storm shaking the global die-casting sector. From bankruptcies in Germany to collapsing volumes in Europe and the brutal rise of EVs, no region or supplier is untouched.

Why are even the “big” foundries going under? What’s behind the silence from OEMs who once sent in rescue teams? And most importantly, what can be done now to survive?

Key Takeaways:

* The Foundry Industry Is in a Financial FreefallWith bankruptcies affecting big names like AE Group and Trimet Bohai, it’s clear this isn’t just a small foundry problem. The entire sector is under pressure, and OEMs are moving quickly to protect their supply chains, often by abandoning suppliers that are struggling.

* Car Production Has Dropped by Half in EuropeBetween 2022 and 2025, European car production is down by 50%. EVs are accelerating this decline in volume per casting, replacing complex multi-part combustion designs with fewer, larger, and heavier castings.

* Nobody Wants to Own a FoundryLarge corporations are spinning off their casting divisions, and investors are staying away. Why? Die casting is no longer seen as a future-facing technology by many boardrooms. Even successful foundries are being split off, sold, or liquidated.

* OEMs Now Prioritize ‘Safe Harbor’ Over LoyaltyGone are the days when OEMs sent in rescue teams. Today, they quickly pull tools from troubled suppliers and move them to more stable partners, often without a second chance: short fuses, fast decisions, and no second chances.

* Overcapacity + Automation = TroubleAutomated lines are only effective at high volumes. However, with shrinking order books, many foundries are now left with expensive, inflexible equipment and insufficient parts to operate it.

Take Action or Be Left Behind

Listen to GN49 to understand how the financial crisis is reshaping the casting world and what it takes to survive. It’s a wake-up call for foundry owners, engineers, and decision-makers across the value chain.

Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes. Until next time, keep casting strong!

Fabian and Staffan